APPLICATION

Applicationn of batter and bread crumb on nuggets

The nuggets are coated with a shallow to thick layer of crispy dough and crumbs : the texture and appearance are intentionally rough. Combinations of operations and ingredients result in tasteful experiences when properly mastered.

Updated Jul 31, 2021 - 10 min Read

BASE

Core products

The core product can be of various types: poultry, cheese, fish, vegetables, fruits.

RECIPE

Ingredients

The batter is prepared with:

  • Wheat flour
  • Finer flour (maize, rice, tapioca) or native starch of the sort
  • Functional starch with expanding, binging, filming, barrier properties
  • Functional ingredients (proteins, hydrocolloids)
  • Fats
  • Leavening agents
  • Flavour and colour
  • Salt, spice
  • Water

The dry ingredients are first mixed together then the liquid is added. To avoid lumps, progressive addition of the liquid and thorough mixing are required. The mix is prepared and stored at low temperature and kept agitated.

The choice of the ingredients will determine the thickness, expansion. In case of prawn nuggets, the coating is very thick; in case of French fries the thickness is very fine providing a barrier effect and retaining crispiness longer. After the liquid coating, the product is dusted and sprinkled with fine to coarse particles: breadcrumb, Japanese crumbs.

PROCESS

How does it work?

The process is a continuous operation.
Batter and crumb applications can be repeated 2 times to increase the thickness.
After coating, the product needs to be stabilized:

  • Deep frying in oil,
  • Cooling during which the oïl is absorbed.

Industrial products are cooled or frozen after coating. Frying is then done just before use The sequences run as follows

1.

Pre-dusting with a fine flour (optional)

5

2.

Batter coating

5

3.

Breadcrumb coating

4.

Deep frying in oil

5

5.

Cooling during which the oïl is absorbed

PROCESS

Coating system

The operation occurs in a series of machines.
Batter coater
Breadcrumb depositor

PROCESS

Coating system

Liquid batter coating with recycling (source GEA)

PRODUCT EVALUATION

How do you measure your success?

Key quality features

The evaluation of the nuggets is complex and carried out best by sensory evaluation.

Texture

The mouthfeel is characteristic. It associates softness and crispiness with limited oil pickup

Aspect and flavour

Roughness and colour appeals. The flavour of the coating enhances the core’s one.

Shelf-life

The nuggets must retain its desred features along the logistic chain until its consumption

Key quality parameters

Factors influencing the product end quality are multiple

Core product

Type, shape, surface texture, moisture

Ingredients

Batter recipe and breadcrumb type

Processing

Liquid and solid application plus frying and cooling conditions